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Yamaha YFZ 2018 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d'importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
OWNER'S MANUAL
YFZ45YSXK
YFZ45YSSK
BW2-F8199-62

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Summary of Contents for Yamaha YFZ 2018

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFZ45YSXK YFZ45YSSK BW2-F8199-62...
  • Page 2 Original instructions Notice originale Manual original PRINTED IN USA 2018.04-0.3×2 CR (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFZ45YSXK YFZ45YSSK WARNING This ATV should not be ridden by anyone under 16 years of age. BW2-F8199-62-E0...
  • Page 4 EBU28981 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.
  • Page 5 Congratulations on your purchase of the Yamaha YFZ45YSXK / YFZ45YSSK. This ATV represents the re- sult of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 6 EBU17331 IMPORTANT MANUAL INFORMATION EBU17344 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 7 Please check your local riding laws and regulations before operating this ATV. EBU17411 YFZ45YSXK / YFZ45YSSK OWNER’S MANUAL ©2019 by Yamaha Motor Co., Ltd. 1st edition, March 2018 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 8: Table Of Contents

    EBU17421 TABLE OF CONTENTS LOCATION OF THE WARNING AND Seat ............4-10 SPECIFICATION LABELS ......1-1 Front shock absorbers ......4-11 Rear shock absorbers ......4-15 SAFETY INFORMATION ........2-1 Handlebar position ........4-23 DESCRIPTION..........3-1 PRE-OPERATION CHECKS ......5-1 Left view............3-1 Fuel ............. 5-4 Right view............3-1 Engine oil ............
  • Page 9 RIDING YOUR ATV ........7-1 Coolant ............. 8-20 GETTING TO KNOW YOUR ATV ....7-2 Cleaning the air filter element ....8-21 RIDE WITH CARE AND GOOD Cleaning the spark arrester ...... 8-25 JUDGMENT ..........7-2 Adjusting the throttle lever free play..8-28 BE CAREFUL WHERE YOU RIDE....
  • Page 10 Battery............8-43 Replacing the fuse ........8-46 Replacing a headlight bulb .......8-46 Adjusting a headlight beam ......8-49 Brake/tail light ...........8-49 Removing a wheel........8-49 Installing a wheel........8-50 Troubleshooting ........8-50 Troubleshooting charts ......8-52 CLEANING AND STORAGE ......9-1 Cleaning ............9-1 Storage............9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION .......11-1 Identification numbers ......11-1 INDEX............12-1...

  • Page 11: Location Of The Warning And Specification Labels

    Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a re- placement label from your Yamaha dealer.
  • Page 12 YAMAHA 1HP-F811R-00 YAMAHA 1P0-F816R-00...
  • Page 13 35.0 kPa 0.35 kgf/cm² 0.35 kgf/cm² 5.0 psi 5.0 psi YAMAHA 3C2-F816P-00 1TD-F816M-M0 Use PREMIUM unleaded gasoline with min. 97 octane (RON). Nur Super Bleifrei mit Mindestoktanzahl 97 (ROZ) tanken. Utilice gasolina sin plomo que tenga como mínimo 97 octanos(RON).
  • Page 14 YAMAHA MOTOR CO., LTD. SHIZUOKA JAPAN YAMAHA 4GB-2155A-00 1HP-F2259-21...
  • Page 15 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER use on paved roads. ALWAYS use an approved helmet and NEVER carry passengers. protective gear.
  • Page 16 EN228 fuel identification mark. Adjust the tire pressure. Gasoline of ethanol 5% or less can be used. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or **.* kPa **.* kPa death. *.** kgf/cm² *.** kgf/cm²...

  • Page 17: Safety Information

    EBU17432 SAFETY INFORMATION SAFETY INFORMATION  Never allow a child under age 16 to operate an EBU29375 ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 18  Never operate at speeds too fast for your skills  Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
  • Page 19  Never operate an ATV in fast flowing water or in technique described in this manual on level ground. Avoid crossing the side of a steep hill if water deeper than that recommended in this possible. manual. Remember that wet brakes may have ...
  • Page 20 In the event of an accident tention. If necessary, contact your riding party 1. If serious injuries are incurred, you may be or local authorities to let them know where safer staying next to your vehicle; it may you are and what has happened. shield you from oncoming riders.
  • Page 21 This im- While you may find aftermarket products similar in proper position limits the freedom of movement design and quality to genuine Yamaha accesso- of the operator and may limit control ability, ries, recognize that some aftermarket accessories...
  • Page 22  Do not run engine outdoors where engine EWB00073 WARNING exhaust can be drawn into a building through openings such as windows and doors. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nau- sea, confusion, and eventually death.

  • Page 23: Description

    EBU17681 DESCRIPTION EBU17691 EBU17701 Left view Right view 1. Front shock absorber 1. Spark arrester 2. Engine oil tank filler cap 2. Fuse 3. Rear brake fluid reservoir 3. Fuel tank cap 4. Battery 4. Oil filter element 5. Shift pedal 5.

  • Page 24: Controls And Instruments

    EBU17715 Controls and instruments 1. Clutch lever 2. Parking brake lever 3. Handlebar switches 4. Main switch 5. Front brake fluid reservoir 6. Throttle lever 7. Brake lever...

  • Page 25: Instrument And Control Functions

    EBU17739 INSTRUMENT AND CONTROL FUNCTIONS EBU29913 EBU29383 Main switch Indicator light and warning lights 1. Main switch 1. Fuel level warning light “ ” 2. Engine trouble warning light “ ” “ ” (on) 3. Coolant temperature warning light “ ”...
  • Page 26 “ ” (on), or if the warning The electrical circuit of the warning light can be light remains on, have a Yamaha dealer check the checked by setting the engine stop switch to “ ”...

  • Page 27: Handlebar Switches

    “ ” (on), or if the warning tion. The engine will not start or run when this light remains on, have a Yamaha dealer check the switch is set to “ ”. electrical circuit.

  • Page 28: Throttle Lever

    starter will not have enough power to crank the EBU18325 Speed limiter engine. If this should happen, remove the bat- tery and recharge it. (See page 8-43.) EBU18285 Throttle lever 1. Locknut 2. Adjusting screw 3. No more than 12 mm (0.47 in) The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to 1.

  • Page 29: Clutch Lever

    the adjusting screw in direction (b). Do not The clutch lever is located on the left side of the turn the adjusting screw out more than 12 handlebar. To disengage the clutch, pull the clutch mm (0.47 in) or the throttle cable could be lever toward the handlebar grip.

  • Page 30: Brake Pedal

    The brake lever is located on the right side of the The brake pedal is located on the right side of the handlebar. To apply the front brake, pull the brake ATV. To apply the rear brake, push down on the lever toward the handlebar grip.

  • Page 31: Shift Pedal

    braking performance which could cause an accident. You could also wear out the brakes prematurely. EBU18532 Shift pedal 1. Parking brake lever (unlocked position) EWB00221 WARNING  Always set the parking brake before starting the engine. The ATV could start moving un- expectedly if the parking brake is not ap- 1.

  • Page 32: Fuel Tank Cap

    of sparks, open flames, or other sources of EBU37980 Fuel tank cap ignition such as the pilot lights of water heat- ers and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole.

  • Page 33: Fuel

    3. Wipe up any spilled fuel immediately. Recommended fuel: NOTICE: Immediately wipe off spilled fuel Premium unleaded gasoline only with a clean, dry, soft cloth, since fuel may Fuel tank capacity: deteriorate painted surfaces or plastic 10 L (2.6 US gal, 2.2 Imp.gal) parts.

  • Page 34: Seat

    About the recommended fuel EBU26734 Seat Use RON 97 octane or higher. If knocking or ping- ing occurs, try a different brand or higher octane To remove the seat gasoline. Gasoline containing ethanol can be used if the ethanol content does not exceed 10% (E10). Gasoline containing methanol is not recommend- ed because it can cause damage to the fuel sys- tem or vehicle performance problems.

  • Page 35: Front Shock Absorbers

    Notes on adjusting the suspension Insert the projections on the front of the seat into  A special wrench can be obtained at a Yamaha the seat holders, and then push down on the seat dealer to make the spring preload adjustment.
  • Page 36 ECB00091 NOTICE  The spring preload setting is determined by Never turn an adjusting mechanism beyond measuring distance A, shown in the illustration. the minimum and maximum settings.  The shorter distance A is, the greater the spring preload. The longer distance A is, the lesser the Spring preload spring preload.
  • Page 37 1. Distance A 1. Rebound damping force adjusting screw 3. Tighten the locknut to the specified torque. Rebound damping force settings: NOTICE: Always tighten the locknut Minimum (soft): against the adjusting nut, and then tighten 30 click(s) in direction (b) it to the specified torque.
  • Page 38 Compression damping force Fast compression damping force settings: Minimum (soft): Fast compression damping force 2 turn(s) out from the fully turned in posi- Turn the fast compression damping force adjust- tion ing bolt in direction (a) to increase the fast com- Standard: pression damping force.

  • Page 39: Rear Shock Absorbers

     Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha deal- 1. Slow compression damping force adjusting screw er for any service. Slow compression damping force settings:...
  • Page 40 Notes on adjusting the suspension  A special wrench can be obtained at a Yamaha dealer to make the spring preload adjustment.  When adjusting the damping force settings, turn the adjuster in direction (a) until it stops, and then count the turns or clicks in direction (b).
  • Page 41 1. Clamp screw 1. Bolt 2. Collar 4. Remove the air filter case holding plate by re- 3. Air filter case holding plate moving the bolts and collars. 5. Remove the bolts, and then remove the air fil- ter case by disconnecting it from the air in- take duct.
  • Page 42 7. Loosen the clamp screw at the throttle body side, and then disconnect the air intake duct from the throttle body. 1. Air filter case 2. Bolt 6. Disconnect the coupler. 1. Clamp screw 2. Air intake duct 8. Loosen the locknut. 9.
  • Page 43 Spring preload setting: Minimum (soft): Distance A = 286.5 mm (11.28 in) Standard: Distance A = 278.0 mm (10.94 in) Maximum (hard): Distance A = 266.5 mm (10.49 in) 1. Locknut 2. Spring preload adjusting nut 3. Special wrench  The spring preload setting is determined by measuring distance A, shown in the illustration.
  • Page 44 15. Install the air filter case holding plate by in- Tightening torque: stalling the bolts and collars, and then tighten Locknut: the bolts to the specified torque. 30 N·m (3.0 kgf·m, 22 lb·ft) Tightening torque: 11. Connect the air intake duct to the throttle Air filter case holding plate bolt: body, and then tighten the clamp screw at the 7 N·m (0.7 kgf·m, 5.2 lb·ft)
  • Page 45 Fast compression damping force Turn the fast compression damping force adjust- ing bolt in direction (a) to increase the fast com- pression damping force. Turn in direction (b) to decrease the fast compression damping force. 1. Rebound damping force adjusting screw Rebound damping force settings: Minimum (soft): 30 click(s) in direction (b)
  • Page 46 Fast compression damping force settings: Minimum (soft): 2 turn(s) out from the fully turned in posi- tion Standard: 1-1/4 turn(s) out from the fully turned in position Maximum (hard): Adjusting bolt fully turned in Slow compression damping force 1. Slow compression damping force adjusting screw Turn the slow compression damping force adjust- ing screw in direction (a) to increase the slow com- Slow compression damping force settings:...

  • Page 47: Handlebar Position

    Yamaha deal- 1. Handlebar er for any service. EBU29403 Handlebar position The handlebar can be adjusted to one of two po- sitions to suit the rider’s preference. Have a Yamaha dealer adjust the position of the handle- bar. 4-23...

  • Page 48: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 49 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-4, 8-29, 8-30, 8-32 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.
  • Page 50 ITEM ROUTINE PAGE • Make sure that operation is smooth. Lubricate lever pivoting points Brake and clutch levers 8-39 if necessary. Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. Instruments, lights and • Check operation, and correct if necessary. switches...

  • Page 51: Fuel

    Yamaha dealer check the brake sys- EBU19713 Front and rear brakes tem. Brake lever and brake pedal  Check that there is no free play in the brake le- ver. If there is free play, have a Yamaha dealer check the brake system.

  • Page 52: Throttle Lever

    Check the operation of the throttle lever. It must also cause the tire to dislodge from the rim un- open smoothly and spring back to the idle position der severe riding conditions. [EWB02542] when released. Have a Yamaha dealer correct if necessary. Recommended tire pressure: Front EBU19771 35.0 kPa (0.350 kgf/cm², 5.0 psi)
  • Page 53 A low-pressure tire gauge is included as standard air valves. After extensive tests, only the tires list- equipment with your vehicle. (See page 8-2.) ed below are approved for this model by Yamaha. When using the tire pressure gauge, make two EWB02552...

  • Page 54: Chassis Fasteners

    Front: Manufacturer/model: MAXXIS/MS21 Size: AT21 x 7R10 Rear: Manufacturer/model: MAXXIS/MS22 Size: AT20 x 10R9 Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort.

  • Page 55: Operation

    3. Shift the transmission into neutral. The neutral vent any loss of control, which could cause an indicator light should come on, if it does not accident or injury. come on, have a Yamaha dealer check the electrical circuit. EBU29954 Starting the engine...

  • Page 56: Shifting

    If the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt.
  • Page 57 4. Open the throttle gradually and at the same shifting can cause the tires to lose traction, reduc- time, release the clutch lever slowly. ing control and increasing the possibility of an ac- WARNING! Opening the throttle abruptly cident. or releasing the clutch lever too quickly EWB00712 WARNING could make the ATV wheelie, which would...

  • Page 58: Engine Break-In

    320 km (200 mi) or 20 engine break-in period, immediately have a hours of operation. For this reason, you should fol- Yamaha dealer check the ATV. low the engine break-in instructions carefully. Since the engine is brand new, do not put an ex-...

  • Page 59: Parking On A Slope

    EBU20922 ing brake, and then block the front and rear Genuine Yamaha Accessories wheels with rocks or other objects. Choosing accessories for your ATV is an impor- tant decision. Genuine Yamaha Accessories, which are available only from a Yamaha dealer,...
  • Page 60  Accessories should be rigidly and securely and accessories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to mounted. An accessory which can shift position test the products that these aftermarket compa- or come off while you are riding could affect nies produce.
  • Page 61  Tie down cargo securely to the carriers. Make curely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater dis- sure cargo in the trailer cannot move around. A tance for braking. shifting load can cause an accident. ...

  • Page 62: Riding Your Atv

    EBU21142 RIDING YOUR ATV...

  • Page 63: Getting To Know Your Atv

    RIDE WITH CARE AND GOOD JUDGMENT EBU21619 Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01382 This ATV is intended for recreational use by expe- WARNING rienced operators only. This section, Riding your  Do not operate this ATV or allow anyone else ATV, provides general ATV riding instructions for to operate it without proper instruction.
  • Page 64 the time to learn the basic techniques well before This ATV is designed to carry the operator only attempting more difficult maneuvers. Become fa- – passengers prohibited. miliar with this ATV at slow speeds first, even if you The long seat is to allow the operator to shift posi- are an experienced operator.
  • Page 65 Apparel Always wear the following to reduce risk of injury in an accident:  Approved motorcycle helmet that fits properly  Eye protection (goggles, helmet face shield, or protective eyewear)  Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 66 fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See page 4-4.) Pre-operation checks Always inspect your ATV each time you use it to...
  • Page 67  Do not exceed the maximum loading limits During operation for the vehicle (see “MAXIMUM LOADING Always keep your feet on the footrests during op- LIMIT” below or vehicle labeling). eration; otherwise, they may contact the rear  Make sure the load does not interfere with wheels.
  • Page 68 ATV should the engine has stopped. To reduce the risk of fire be genuine Yamaha or equivalent components during operation or after leaving the ATV, do not designed for use on this ATV and should be in- let brush, grass and other materials collect under stalled and used according to instructions.

  • Page 69: Be Careful Where You Ride

    next to other hot parts. Check under the vehicle BE CAREFUL WHERE YOU RIDE after operating in areas where combustible mate- This ATV is designed for use on unpaved surfaces rials may have collected. Do not idle or park the only.
  • Page 70 Watch carefully for other vehicles. Make sure you have enough time to react to hidden rocks, know your country’s laws and regulations before bumps, or holes. Go slowly and be extra care- you ride on unpaved public streets or roads. Do ful when operating on unfamiliar terrain.
  • Page 71 terrain could cause loss of traction or ATV con- trol, which could result in an accident, includ- ing an overturn. [EWB01542] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

  • Page 72: Turning Your Atv

    NOTICE: Do not shift gears without Select a large, flat, unpaved area to become famil- trol. [EWB02632] iar with your ATV. Make sure that this area is free releasing the throttle. Damage to the engine or of obstacles and other riders. You should practice drive train may occur.
  • Page 73 To achieve maximum traction on unpaved surfac- es, the two rear wheels turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning tech- nique must be used to allow the ATV to make turns quickly and easily.

  • Page 74: Climbing Uphill

     Shift your weight forward. Once you have learned this technique, you should  Never open the throttle suddenly or make be able to perform it at higher speeds or in tighter curves. sudden gear changes. The ATV could flip Improper riding procedures such as abrupt throt- over backwards.
  • Page 75 Do not attempt to climb hills until you have mas- tered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
  • Page 76 It is important when climbing a hill to make sure If you start to roll backwards, DO NOT apply the that your weight is transferred forward on the ATV. rear brake, and apply the front brake gradually. This can be accomplished by leaning forward and, The ATV could easily tip over backwards.

  • Page 77: Riding Downhill

     Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills.  Shift your weight backward and to the up side of the hill.

  • Page 78: Crossing A Slope

    Whenever possible, ride your ATV straight down- CROSSING A SLOPE hill. Avoid sharp angles which could allow the ATV EWB01633 WARNING to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to ob- Improperly crossing hills or turning on hills stacles which may appear.

  • Page 79: Crossing Through Shallow Water

    As you travel across a slope, lean your body in the CROSSING THROUGH SHALLOW WATER uphill direction. It may be necessary to correct the EWB01642 WARNING steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on Operating this vehicle through deep or fast- slopes, be sure not to make sharp turns either up flowing water can lead to loss of control or an...
  • Page 80 After riding your ATV in water, be sure to drain the Test your brakes after leaving the water. If neces- trapped water by removing the check hose at the sary, apply them several times to let friction dry bottom of the air filter case. NOTICE: Undrained out the linings.

  • Page 81: Riding Over Rough Terrain

    accident. Be sure to keep your feet firmly mounted on the footrests at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING EWB01663 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 82: What To Do If

    To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain If the rear wheels of your ATV start to slide side- should be chosen carefully before attempting ways, control can usually be regained (if there is...

  • Page 83: What To Do

     If your ATV is traversing a sloping surface: WHAT TO DO...  If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again.

  • Page 84: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 85: Owner's Manual And Tool Kit

    Make sure to protect the Owner’s Manual If you do not have the tools or experience required by putting it in the plastic bag, then by placing the for a particular job, have a Yamaha dealer perform bag in the document pouch. it for you.

  • Page 86: Periodic Maintenance Chart: Emission Control System

     For odometer or hour meter-equipped vehicles, follow the month maintenance interval if the ATV isn’t ridden for the stated mileage or engine operating hours.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 87 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 88: Periodic Maintenance Chart: General Maintenance And Lubrication

     For odometer or hour meter-equipped vehicles, follow the month maintenance interval if the ATV isn’t ridden for the stated mileage or engine operating hours.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 89 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses •...
  • Page 90 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours √ √ √ Drive chain roller • Check for wear and replace if necessary. • Make sure that all nuts, bolts, and screws are √...
  • Page 91 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours Moving parts and √ √ √ √ • Lubricate. cables • Check operation. • Check throttle lever free play, and adjust if neces- √...
  • Page 92 • Replace the brake hoses every four years and if cracked or damaged.

  • Page 93: Removing And Installing The Cowling And Panels

    EBU30131 Removing and installing the cowling and panels The cowling and panels shown need to be re- moved to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed.
  • Page 94 5. Install the fuel tank cap by turning it clock- wise. To install the panel 1. Remove the fuel tank cap by turning it coun- terclockwise. 2. Place the panel in the original position, and then install the quick fasteners. NOTICE: When installing the panel, be sure not to pinch the cables or wires.
  • Page 95 Panels B and C To remove a panel 1. Remove panel A. 2. Pull the panel off. 2. Install panel A. Cowling To remove the cowling 1. Remove panels A, B and C. To install a panel 2. Loosen the quick fasteners, and then take the 1.

  • Page 96: Checking The Spark Plug

    The spark plug is an important engine component, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- 1.

  • Page 97: Engine Oil And Oil Filter Element

    Specified spark plug: Tightening torque: NGK/CR8E Spark plug: 13 N·m (1.3 kgf·m, 9.6 lb·ft) Before installing the spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. If a torque wrench is not available when installing the spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight.
  • Page 98 To achieve the proper engine oil temperature for an accurate oil level reading, the engine must have first completely cooled down, and then warmed up again for several minutes to normal operating temperature. 3. Remove the engine oil tank filler cap, and wipe the engine oil dipstick off with a clean rag.
  • Page 99 When adding oil, be careful not to overfill the en- gine oil tank; the oil level rises faster starting from the half-level mark on the dipstick. 6. Check the O-ring for damage, and replace it if necessary. 7. Insert the dipstick into the engine oil tank filler hole, and then tighten the engine oil tank filler cap.
  • Page 100 1. Engine oil tank drain bolt 1. Crankcase engine oil drain bolt 2. Gasket 2. Gasket 6. Remove the crankcase engine oil drain bolt and its gasket. Skip steps 7–10 if the oil filter element is not being replaced. 7. Remove the oil filter element cover by remov- ing the bolts.
  • Page 101 1. Oil filter element cover 1. Oil filter element 2. Bolt 2. O-ring 8. Remove the oil filter element and the O-rings. 9. Install a new oil filter element and new O- rings. Make sure that the O-rings are properly seated. 10.
  • Page 102 11. Install the crankcase engine oil drain bolt, the ECB00301 NOTICE engine oil tank drain bolt and their new gas-  In order to prevent clutch slippage (since the ket, and then tighten the bolts to their speci- fied torques. engine oil also lubricates the clutch), do not mix any chemical additives.

  • Page 103: Coolant

    1.25 L (1.32 US qt, 1.10 Imp.qt) The coolant should be between the minimum and If genuine Yamaha coolant is not available, use an maximum level marks. ethylene glycol antifreeze containing corrosion in- hibitors for aluminum engines and mix with dis- tilled water at a 1:1 ratio.

  • Page 104: Cleaning The Air Filter Element

    EBU29863 Changing the coolant The coolant must be changed at the intervals specified in the periodic maintenance chart. Have a Yamaha dealer change the coolant. WARNING! Never attempt to remove the radiator cap when the engine is hot. [EWB04300] EBU2680A...
  • Page 105 1. Air filter case check hose 1. Air filter case cover 2. Air filter case cover holder 1. Park the ATV on a level surface. 4. Fully loosen the wing bolt. 2. Remove the seat. (See page 4-10.) 5. Remove the air filter element together with 3.
  • Page 106 1. Air filter element 1. Sponge material 2. Washer 2. Air filter element frame 3. Wing bolt 8. Wash the sponge material gently but thor- 6. Remove the wing bolt and washer from the air oughly in solvent. WARNING! Always use filter element.
  • Page 107 10. Check the sponge material and replace it if damaged. 14. Install the washer onto the air filter element 11. Apply Yamaha foam air filter oil or other qual- frame, and then insert the wing bolt into the hole in the air filter element frame. NOTICE: ity foam air filter oil to the sponge material.

  • Page 108: Cleaning The Spark Arrester

    17. Install the seat. The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas. Each time the air filter element main- tenance is performed, check the air inlet of the air filter case for obstructions.
  • Page 109 1. Tailpipe cover 1. Bolt 2. Bolt 2. Retainer 3. Tailpipe 2. Remove the retainer by removing the bolts, 4. Gasket and then remove the tailpipe and gasket from 3. Tap the tailpipe lightly, and then use a wire the muffler. brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing.
  • Page 110 Tightening torque: Tailpipe cover bolt: 8 N·m (0.8 kgf·m, 5.9 lb·ft) EWB02342 WARNING Always let the exhaust system cool prior to touching exhaust components. Do not start the engine with the spark arrester removed. Sparks or exhaust particulate can cause eye injury, burns, or start a fire. 1.

  • Page 111: Adjusting The Throttle Lever Free Play

    The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- 1. Rubber cover brication chart.

  • Page 112: Checking The Front And Rear Brake Pads

    If a brake pad has worn to the point that the wear indicator grooves have almost dis- appeared, have a Yamaha dealer replace the The wheels need to be removed to check the brake pads as a set.

  • Page 113: Checking The Brake Fluid Level

    Front brake 1. Wear indicator groove 1. Minimum level mark EBU29502 Rear brake Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid lev- el with the top of the reservoir level. Replenish the brake fluid if necessary.

  • Page 114: Changing The Brake Fluid

    If the brake fluid level goes down sud- only DOT 4 brake fluid from a sealed contain- denly, have a Yamaha dealer check the cause be-  Use only the specified brake fluid; otherwise, fore further riding.

  • Page 115: Checking The Front Brake Lever Free Play

    Yamaha dealer adjust it. 1. No brake lever free play There should be no free play at the brake lever end. If there is free play, have a Yamaha dealer in- spect the brake system. 8-32...

  • Page 116: Adjusting The Parking Brake Free Play

    1. Release the parking brake by moving the If the cable length cannot be adjusted to specifi- parking brake lever to the right. cation, consult a Yamaha dealer. 2. Fully loosen the locknut and the adjusting bolt at the rear brake caliper.

  • Page 117: Brake Light Switches

    [ECB00522] switch should be adjusted by a Yamaha dealer. Turn the rear brake light switch adjusting nut while Tightening torque: holding the brake light switch in place. To make...

  • Page 118: Adjusting The Clutch Lever Free Play

    2. Fully turn the adjusting nut at the clutch lever EBU30155 Adjusting the clutch lever free play in direction (a) to loosen the clutch cable. 3. Slide back the rubber cover at the clutch ca- ble. 1. Clutch lever free play 2.

  • Page 119: Drive Chain Slack

    If the specified free play cannot be obtained as de- scribed above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism. EBU26867 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary.
  • Page 120 1. Rear wheel axle pinch bolt 2. Rod 3. Drive chain tensioner 4. Hole A rod can be obtained at a Yamaha dealer to make this adjustment. Tightening torque: Rear axle pinch bolt: 4. Shift the transmission into neutral.

  • Page 121: Lubricating The Drive Chain

    EBU24883 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. ECB00562 NOTICE The drive chain must be lubricated after wash-...

  • Page 122: Checking And Lubricating The Brake And Clutch Levers

    If a cable is damaged or does not move EBU24923 Checking and lubricating the brake smoothly, have a Yamaha dealer check or replace and clutch levers The operation of the brake and clutch levers Recommended lubricant: should be checked before each ride, and the lever Yamaha cable lubricant or other suitable pivots should be lubricated if necessary.

  • Page 123: Checking The Shift Pedal

    If there is play in a wheel hub or if a wheel does not turn smooth- pedal ly, have a Yamaha dealer check the wheel hub The operation of the brake pedal should be bearings. checked before each ride, and the pedal pivot should be lubricated if necessary.

  • Page 124: Lubricating The Swingarm Pivots

    Lubricating the upper and lower arm The swingarm pivots must be lubricated by a pivots Yamaha dealer at the intervals specified in the pe- The upper and lower arm pivots must be lubricat- riodic maintenance and lubrication chart. ed at the intervals specified in the periodic main- tenance and lubrication chart.

  • Page 125: Lubricating The Steering Shaft

    For parts equipped with a grease nipple, use a grease gun. EBU25095 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe- riodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease 8-42...

  • Page 126: Battery

    KEEP OUT OF REACH OF CHILDREN. hands after handling.  It is recommended to have the battery serviced by a Yamaha dealer. To remove the battery 1. Remove the seat. (See page 4-10.) 2. Remove the battery holding plate by remov- ing the bolts.
  • Page 127 3. Disconnect the negative battery lead first, ECB00622 NOTICE then the positive battery lead by removing their bolt. NOTICE: When removing the bat- Never attempt to open the battery or remove tery, the main switch must be off, and the the battery cell seals, as this would permanent- negative lead must be disconnected be- ly damage the battery.
  • Page 128 ECB00942 NOTICE  Always keep the battery charged. Storing the battery in a discharged state for an extended period of time will cause permanent battery damage.  Do not store the battery in an excessively cold or warm place [below freezing or above 30 °C (90 °F)].

  • Page 129: Replacing The Fuse

    1. Fuse 4. If the fuse immediately blows again, have a 2. Spare fuse Yamaha dealer check the electrical system. The fuse holder is located under the seat. (See page 4-10.) EBU30873 If the fuse is blown, replace it as follows.
  • Page 130 3. Remove the socket by pushing it in and turn- ing it counterclockwise, and then remove the burnt-out bulb. 1. Headlight unit 2. Bolt 2. Remove the bulb cover. 1. Socket 4. Place a new headlight bulb into position. NOTICE: Do not touch the glass part of the bulb.
  • Page 131 1. Do not touch the glass part of the bulb. 1. Bulb cover 2. “TOP” mark 5. Install the socket by pushing it in and turning 7. Place the headlight unit in the original posi- it clockwise. tion, and then install the bolt. 6.

  • Page 132: Adjusting A Headlight Beam

    ECB00691 If the brake/tail light does not come on, have a NOTICE Yamaha dealer check it. It is advisable to have a Yamaha dealer make this adjustment. EBU25653 Removing a wheel To raise a headlight beam, turn the headlight 1.

  • Page 133: Installing A Wheel

    However, should your ATV 1. Arrow mark require any repair, take it to a Yamaha dealer, 2. Forward rotating direction whose skilled technicians have the necessary 3. Wheel nut tools, experience, and know-how to service the 2.
  • Page 134 EWB02281 WARNING Do not smoke when checking the fuel system. Fuel can ignite or explode, causing severe inju- ry or property damage. Make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. 8-51...

  • Page 135: Troubleshooting Charts

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the compression. 4. Compression The engine does not start. There is compression.
  • Page 136 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK.  Tap water can be used in an emergency. Change to the recommended coolant as soon as possible.

  • Page 137: Cleaning And Storage

    EBU25861 CLEANING AND STORAGE ter pressure may cause water seepage EBU25903 Cleaning and deterioration of wheel bearings, Frequent, thorough cleaning of your ATV will not brakes, transmission seals and electrical only enhance its appearance but will improve its devices. Many expensive repair bills have general performance and extend the useful life of resulted from improper high-pressure de- many components.

  • Page 138: Storage

    abrasives which may mar the paint or protec- 3. Fill up the fuel tank and add fuel stabilizer (Fu- tive finish. When finished cleaning, start the el Med Rx if available), and then run the en- engine and let it idle for several minutes. gine for 5 minutes to distribute the treated fuel.
  • Page 139 6. Put the frame on stands or blocks to raise all wheels off the ground. (Alternatively, turn the wheels each month to prevent the tires from degrading in one spot.) 7. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.

  • Page 140: Specifications

    EBU25962 SPECIFICATIONS Dimensions: Uncertainty of measurement: 3.0 dB(A) Overall length: A-weighted sound power level: 1795 mm (70.7 in) 99.0 dB(A) at 3750 r/min Overall width: Uncertainty of measurement: 1240 mm (48.8 in) 3.0 dB(A) Overall height: Vibration on seat (EN1032, ISO5008): 1065 mm (41.9 in) Will not exceed 0.5 m/s²...
  • Page 141 Starting system: Coolant quantity: Electric starter Radiator (including all routes): Lubrication system: 1.25 L (1.32 US qt, 1.10 Imp.qt) Dry sump Coolant reservoir (up to the maximum level mark): Engine oil: 0.25 L (0.26 US qt, 0.22 Imp.qt) Recommended brand: Air filter: YAMALUBE Air filter element:...
  • Page 142 Secondary reduction ratio: Recommended: 2.714 (38/14) Front: Final drive: 35.0 kPa (0.350 kgf/cm², 5.0 psi) Chain Rear: Clutch type: 35.0 kPa (0.350 kgf/cm², 5.0 psi) Wet, multiple-disc Minimum: Transmission type: Front: 5-speed 32.0 kPa (0.320 kgf/cm², 4.6 psi) Gear ratio: Rear: 1st: 32.0 kPa (0.320 kgf/cm², 4.6 psi)
  • Page 143 Shock absorber: Neutral indicator light: Gas-hydraulic damper Wheel travel: Fuel level warning light: 250 mm (9.9 in) Rear suspension: Coolant temperature warning light: Type: Engine trouble warning light: Swingarm (link suspension) Spring: Fuses: Coil spring Shock absorber: Main fuse: Gas-hydraulic damper 20.0 A Wheel travel: 280 mm (11.0 in)
  • Page 144 sure level can vary from country. This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk. 10-5...

  • Page 145: Consumer Information

    Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number...
  • Page 146 1. Model label 11-2...

  • Page 147: Index

    INDEX Accessories and loading ..........6-5 Drive chain ..............5-5 Air filter element, cleaning ........... 8-21 Drive chain, lubricating ..........8-38 Drive chain slack ............8-36 Battery ................. 8-43 Brake and clutch levers, checking and lubricating ..8-39 Engine break-in .............. 6-4 Brake fluid, changing ...........
  • Page 148 Storage ................9-2 Suspension, lubricating the upper and lower arm Main switch ..............4-1 pivots ................. 8-41 Maintenance and lubrication chart ........8-5 Swingarm pivots, lubricating ........8-41 Maintenance chart, emission control system ....8-3 Model label ..............11-1 Throttle lever ............4-4, 5-5 Throttle lever free play, adjusting .........8-28 Neutral indicator light .............4-1 Tires ................
  • Page 150 EBU26173 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE NEVER USE NEVER CARRY AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND OR ALCOHOL ROADS PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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